U.S. patent application number 15/242991 was filed with the patent office on 2017-02-09 for two-stage sway bar.
The applicant listed for this patent is TAP Worldwide, LLC. Invention is credited to Sean J. Angues, Jason L. Bennett, Jason M. Miyamoto.
Application Number | 20170036506 15/242991 |
Document ID | / |
Family ID | 54258921 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170036506 |
Kind Code |
A1 |
Miyamoto; Jason M. ; et
al. |
February 9, 2017 |
TWO-STAGE SWAY BAR
Abstract
Sway bars are described that include at least an inner sway bar,
a first outer sway bar, and a second outer sway bar. The sway bar
includes a first coupling portion and a second coupling portion
that can engage and disengage under control from a remote location.
The sway bar includes a larger diameter, outer sway bar assembly
that can be disengaged and a smaller diameter inner sway bar. The
sway bar can include a housing to retain fluid.
Inventors: |
Miyamoto; Jason M.; (San
Diego, CA) ; Angues; Sean J.; (Corona, CA) ;
Bennett; Jason L.; (Chula Vista, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TAP Worldwide, LLC |
Compton |
CA |
US |
|
|
Family ID: |
54258921 |
Appl. No.: |
15/242991 |
Filed: |
August 22, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14681450 |
Apr 8, 2015 |
9463680 |
|
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15242991 |
|
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61977528 |
Apr 9, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60G 21/055 20130101;
B60G 2202/135 20130101; B60G 21/0558 20130101; B60G 21/0556
20130101; B60G 2206/427 20130101 |
International
Class: |
B60G 21/055 20060101
B60G021/055 |
Claims
1-20. (canceled)
21. A sway bar assembly comprising: an outer sway bar assembly
comprising: a first outer sway bar, a first coupling portion
configured to longitudinally slide relative to the first outer sway
bar, a second outer sway bar, a second coupling portion; and an
inner sway bar disposed within the first outer sway bar and the
second outer sway bar, the inner sway bar extending at least the
length of the first outer sway bar or the length of the second
outer sway bar.
22. The sway bar assembly of claim 21, further comprising a
mounting arrangement configured to mount the sway bar assembly to a
vehicle wherein the mounting arrangement comprises a first linking
arm and a second linking arm.
23. The sway bar assembly of claim 22, wherein the first linking
arm and the second linking arm are coupled together through the
inner sway bar and disengageably coupled together through the outer
sway bar assembly.
24. The sway bar assembly of claim 21, further comprising a biasing
element that biases the first coupling portion toward the second
coupling portion such that the first coupling portion and the
second coupling portion mate.
25. The sway bar assembly of claim 24, wherein the sway bar
assembly comprises a remote activator configured to overcome the
force of the biasing element to move the first coupling portion
away from the second coupling portion such that the first coupling
portion and the second coupling portion are separated.
26. The sway bar assembly of claim 21, wherein the first coupling
portion comprise dogs.
27. The sway bar assembly of claim 26, wherein the second coupling
portion comprise dogs.
28. The sway bar assembly of claim 21, further comprising a
housing, wherein the housing encloses the first coupling portion
and the second coupling portion.
29. The sway bar assembly of claim 28, wherein the housing is sized
to permit the sliding of the first coupling portion with respect to
the first outer sway bar to disengage the first coupling portion
from the second coupling portion.
30. The sway bar assembly of claim 28, wherein the housing is
configured to accept an actuation fluid to move the first coupling
portion relative to the second coupling portion.
31. The sway bar assembly of claim 21, wherein the inner sway bar
extends the length of the outer sway bar assembly.
32. A sway bar assembly comprising: an outer sway bar assembly
comprising: a first outer sway bar, a first coupling portion, a
second outer sway bar, a second coupling portion; and an inner sway
bar disposed within the first outer sway bar and the second outer
sway bar, a mounting arrangement configured to mount the sway bar
assembly to a vehicle wherein the mounting arrangement comprises a
first linking arm and a second linking arm, the inner sway bar
extending the distance between the first linking arm and the second
linking arm.
33. The sway bar assembly of claim 32, wherein the first linking
arm and the second linking arm are coupled together through the
inner sway bar and disengageably coupled together through the outer
sway bar assembly.
34. The sway bar assembly of claim 32, wherein the first coupling
portion is configured to longitudinally slide relative to the first
outer sway bar.
35. The sway bar assembly of claim 32, wherein the outer sway bar
assembly extends the distance between the first linking arm and the
second linking arm.
36. A sway bar assembly comprising: an outer sway bar assembly
comprising: a first outer sway bar, a first coupling portion, a
second outer sway bar, a second coupling portion; and an inner sway
bar disposed within the first outer sway bar and the second outer
sway bar, wherein the first outer sway bar and the second outer
sway bar are configured to transmit torque when the first coupling
portion engages the second coupling portion, wherein the inner sway
bar transmits torque when the first coupling portion disengages the
second coupling portion.
37. The sway bar assembly of claim 36, wherein engaging the first
outer sway bar with the second outer sway bar further comprises
engaging dogs of the first coupling portion with dogs of the second
coupling portion.
38. The sway bar assembly of claim 36, wherein engaging the first
outer sway bar with the second outer sway bar further comprises
transmitting torque as if the first outer sway bar and the second
outer sway bar were unitarily formed.
39. The sway bar assembly of claim 36, further comprising a
mounting arrangement configured to mount the sway bar assembly to a
vehicle wherein the mounting arrangement comprises a first linking
arm and a second linking arm.
40. The sway bar assembly of claim 39, wherein the first linking
arm and the second linking arm are coupled together through the
inner sway bar.
Description
INCORPORATION BY REFERENCE TO RELATED APPLICATIONS
[0001] Any and all applications identified in a priority claim in
the Application Data Sheet, or any correction thereto, are hereby
incorporated by reference herein and made a part of the present
disclosure. This application is a continuation of U.S. application
Ser. No. 14/681,450, filed Apr. 8, 2015, which claims the priority
benefit under 35 U.S.C. .sctn.119(e) of U.S. Provisional
Application No. 61/977,528 filed Apr. 9, 2014, the disclosure of
each is hereby incorporated by reference in its entirety and should
be considered a part of this specification.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention generally relates to sway bars. More
particularly, the present invention relates to two-stage sway bars
having a disengagable first stage.
[0004] Description of the Related Art
[0005] A sway bar is part of a vehicle's suspension system and can
be referred to as a stabilizer bar. The sway bar reduces vehicle
roll during certain maneuvers, such as during fast turns or while
traversing certain terrain conditions.
[0006] Front and rear sway bars can be used to connect the front
and rear wheels, respectively. The function of the sway bar is to
transfer force from a first side of the vehicle to a second side of
the vehicle. The sway bar typically includes a horizontal bar that
extends laterally between the wheels. The bar resists torsion
through its stiffness.
[0007] The stiffness, and therefore the anti-roll characteristics,
is due in large part to the diameter of the sway bar. A larger
diameter sway bar tends to keep the vehicle more level while a
smaller diameter sway bar allows the body of the vehicle to roll
more with the terrain or other maneuver. For certain operations,
such a rock crawling, a smaller diameter sway bar is preferred over
a larger diameter sway bar to allow the wheels of the vehicle to
traverse the terrain. For other operations, such as everyday
driving, a larger diameter sway bar is preferred to reduce vehicle
roll.
[0008] Although sway bars have been in use for a significant period
of time, there is a demand for continued improvement in the design
and operation of sway bars, especially in sway bars intended for
use in certain environments, such as off-road operation. For
example, there is a constant push to reduce the stiffness of sway
bars during certain driving conditions, while retaining
functionality (including anti-roll characteristics) during other
driving conditions.
SUMMARY OF THE INVENTION
[0009] An embodiment is a sway bar assembly, including an outer
sway bar having a first outer sway bar and a second outer sway bar.
An inner sway bar is disposed within the outer sway bar. The first
outer sway bar includes a first coupling and the second outer sway
bar includes a second coupling, wherein the first coupling and the
second coupling are configured to be joined or to mate. In some
configurations, the sway bar includes a biasing element that biases
the first coupling toward the second coupling such that the first
coupling and the second coupling mate. A remote activator can be
connected to the sway bar assembly. The remote activator can be
configured to overcome the force of the biasing element to move the
first coupling away from the second coupling such that the first
coupling and the second coupling do not mate.
[0010] In some arrangements, the sway bar assembly includes
engagement features. For example, the first outer sway bar includes
an engagement feature configured to complement an engagement
feature of the first coupling. The second outer sway bar can
include an engagement feature configured to complement an
engagement feature on the second coupling. In some embodiments, the
engagement feature is a set of longitudinally extending spines on
the outer surfaces of the first and second outer sway bars
configured to complement a set of longitudinally extending spines
on the inner surface of the first and second couplings.
[0011] In some arrangements, the first coupling and the second
coupling are retained within a housing. The housing is sized and
configured to permit sliding of the first coupling with respect to
the first outer sway bar to disengage the first coupling from the
second coupling. The housing is configured to accept an actuation
fluid to move the first coupling relative to the second coupling.
The sway bar assembly can include one or more seals that reduce or
eliminate the likelihood of actuation fluid escape. The sway bar
assembly can include one or more valves to discharge the actuation
fluid. The sway bar assembly can include one or more inlets to
accept the actuation fluid. In some embodiments, the actuation
fluid is a liquid. In other embodiment, the actuation fluid is a
gas.
[0012] In some configurations, a mounting arrangement has a first
hubcap and a second hubcap configured to engage the inner sway bar.
The inner sway bar may include an engagement feature to reduce or
eliminate the likelihood of rotation of the inner sway bar with
respect to the first hubcap and a second hubcap. The first hubcap
may couple to a first linking arm and the second hubcap may couple
to a second linking arm. The first linking arm can couple to the
first outer sway bar and the second linking arm can couple to the
second outer sway bar. The first linking arm and the first outer
sway bar can include an engagement feature. The second linking arm
and the second outer sway bar can include an engagement
feature.
[0013] An embodiment involves a sway bar assembly, including an
outer sway bar comprising a first outer sway bar and a second outer
sway bar. The sway bar includes an inner sway bar within the outer
sway bar. The sway bar assembly includes a first coupling and a
second coupling. A mounting arrangement permits the sway bar
assembly to be mounted relative to a set of wheels. The mounting
arrangement comprises a first hubcap and a second hubcap coupled to
the inner sway bar. A position of the first coupling is adjustable
in a longitudinal direction of the sway bar to permit the
disengagement of the first coupling and the second coupling. The
first coupling is movable against a biasing force to disengage the
second coupling.
[0014] In some arrangements, the first coupling has a first set of
dogs. The second coupling has a second set of dogs. The first set
of dogs of the first coupling are configured engage recesses
defined within the second set of dogs of the second coupling. The
first set of dogs can be unitarily formed with the first coupling.
The second set of dogs can be unitarily formed with the second
coupling.
[0015] In some embodiments, a sway bar assembly is provided. The
sway bar assembly can include an outer sway bar assembly. The outer
sway bar assembly can include a first outer sway bar, a first
coupling portion connected to the first outer sway bar, a second
outer sway bar, a second coupling portion connected to the second
outer sway bar. The first coupling portion and the second coupling
portion can disengagably mate. The sway bar assembly can include a
biasing element that biases the first coupling portion toward the
second coupling portion such that the first coupling portion and
the second coupling portion mate. The sway bar assembly can include
inner sway bar disposed within the outer sway bar assembly.
[0016] The sway bar assembly can include a remote activator
configured to overcome the force of the biasing element to move the
first coupling portion away from the second coupling portion such
that the first coupling portion and the second coupling portion are
separated. The sway bar assembly can include an engagement feature
preventing the rotation of the first coupling portion relative to
the first outer sway bar. The sway bar assembly can include an
engagement feature preventing the rotation of the second coupling
portion relative to the second outer sway bar. The sway bar
assembly can include a housing, wherein the housing contains the
first coupling portion and the second coupling portion. In some
embodiments, the housing is sized to permit the sliding of the
first coupling portion with respect to the first outer sway bar to
disengage the first coupling portion from the second coupling
portion. In some embodiments, the housing is configured to accept
an actuation fluid to move the first coupling portion relative to
the second coupling portion. In some embodiments, the sway bar
assembly comprises one or more seals that prevent the escape of the
actuation fluid. In some embodiments, the sway bar assembly
includes one or more ports through which actuation fluid can pass
in and out of the housing. In some embodiments, the actuation fluid
is liquid. In some embodiments, the actuation fluid is gas. The
sway bar assembly can include a first hubcap and a second hubcap
configured to engage the inner sway bar. In some embodiments, the
inner sway bar comprises an anti-rotation feature to prevent
rotation of the inner sway bar with respect to the first hubcap and
the second hubcap.
[0017] In some embodiments, a sway bar assembly is provided. The
sway bar assembly can include an outer sway bar assembly. The outer
sway bar assembly can include a first outer sway bar, a first
coupling portion coupled to the first outer sway bar, a second
outer sway bar, and a second coupling portion coupled to the second
outer sway bar. The sway bar assembly can include an inner sway bar
disposed within the outer sway bar assembly. The sway bar assembly
can include a mounting arrangement to mount the sway bar assembly
to a vehicle wherein the mounting arrangement comprises a first
linking arm and a second linking arm coupled together through the
inner sway bar and disengageably coupled together through the outer
sway bar assembly. In some embodiments, the first coupling portion
is movable against a biasing force to disengage from the second
coupling portion. In some embodiments, the first coupling portion
has a plurality of teeth and the second coupling portion has a
corresponding plurality of teeth. In some embodiments, the teeth
can be unitarily formed with the first coupling portion and the
second coupling portion.
[0018] In some embodiments, a sway bar assembly is provided. The
sway bar assembly can include an outer sway bar assembly. The outer
sway bar assembly can include a first outer sway bar, a first
coupling portion configured to longitudinally slide relative to the
first outer sway bar, a second outer sway bar, and a second
coupling portion. The sway bar assembly can include an inner sway
bar disposed within the first outer sway bar and the second outer
sway bar.
[0019] The sway bar assembly can include a mounting arrangement
configured to mount the sway bar assembly to a vehicle wherein the
mounting arrangement comprises a first linking arm and a second
linking arm. In some embodiments, the first linking arm and the
second linking arm are coupled together through the inner sway bar
and disengageably coupled together through the outer sway bar
assembly. The sway bar assembly can include a biasing element that
biases the first coupling portion toward the second coupling
portion such that the first coupling portion and the second
coupling portion mate. The sway bar assembly can include a remote
activator configured to overcome the force of the biasing element
to move the first coupling portion away from the second coupling
portion such that the first coupling portion and the second
coupling portion are separated. The sway bar assembly can include a
first engagement feature preventing the rotation of the first
coupling portion relative to the first outer sway bar. In some
embodiments, the first engagement feature comprises teeth. The sway
bar assembly can include a second engagement feature preventing the
rotation of the second coupling portion relative to the second
outer sway bar. In some embodiments, the second engagement feature
comprises teeth. In some embodiments, the teeth can be unitarily
formed with the second coupling portion. The sway bar assembly can
include a housing, wherein the housing encloses the first coupling
portion and the second coupling portion. In some embodiments, the
housing is sized to permit the sliding of the first coupling
portion with respect to the first outer sway bar to disengage the
first coupling portion from the second coupling portion. In some
embodiments, the housing is configured to accept an actuation fluid
to move the first coupling portion relative to the second coupling
portion. In some embodiments, the sway bar assembly comprises one
or more seals to prevent the escape of the actuation fluid. The
sway bar assembly can include one or more ports through which the
actuation fluid can pass in and out of the housing. In some
embodiments, the actuation fluid is liquid. In some embodiments,
the actuation fluid is gas. The sway bar assembly can include a
first hubcap and a second hubcap configured to engage the inner
sway bar. In some embodiments, the inner sway bar comprises an
anti-rotation feature to prevent rotation of the inner sway bar
with respect to the first hubcap and the second hubcap. In some
embodiments, the first coupling portion includes dogs. In some
embodiments, the second coupling portion includes dogs. In some
embodiments, dogs can be unitarily formed with the first coupling
portion and the second coupling portion.
[0020] In some embodiments, a sway bar assembly is provided. The
sway bar assembly can include an outer sway bar assembly. The outer
sway bar assembly can include a first outer sway bar, a first
coupling portion configured to longitudinally slide relative to the
first outer sway bar, a second outer sway bar, and a second
coupling portion. The sway bar assembly can include a biasing
element that biases the first coupling portion into engagement with
the second coupling portion.
[0021] The sway bar assembly can include an inner sway bar disposed
within the outer sway bar assembly. The sway bar assembly can
include a mounting arrangement configured to mount the sway bar
assembly to a vehicle wherein the mounting arrangement comprises a
first linking arm and a second linking arm. In some embodiments,
the first linking arm and the second linking arm are coupled
together through the inner sway bar and disengageably coupled
together through the outer sway bar assembly. The sway bar assembly
can include a remote activator configured to overcome the force of
the biasing element to move the first coupling portion away from
the second coupling portion such that the first coupling portion
and the second coupling portion are separated. The sway bar
assembly can include a first engagement feature preventing the
rotation of the first coupling portion relative to the first outer
sway bar. The sway bar assembly can include a second engagement
feature preventing the rotation of the second coupling portion
relative to the second outer sway bar. The sway bar assembly can
include a housing, wherein the housing encloses the first coupling
portion and the second coupling portion. In some embodiments, the
housing is sized to permit the sliding of the first coupling
portion with respect to the first outer sway bar to disengage the
first coupling portion from the second coupling portion. In some
embodiments, the housing is configured to accept an actuation fluid
to move the first coupling portion relative to the second coupling
portion. In some embodiments, the sway bar assembly comprises one
or more seals to prevent the escape of the actuation fluid. In some
embodiments, the sway bar assembly includes one or more ports
through which actuation fluid can pass in and out of the housing.
In some embodiments, the actuation fluid is liquid. In some
embodiments, the actuation fluid is gas. The sway bar assembly can
include a first hubcap and a second hubcap configured to engage the
inner sway bar. In some embodiments, the inner sway bar comprises
an anti-rotation feature to prevent rotation of the inner sway bar
with respect to the first hubcap and the second hubcap.
[0022] In some embodiments, a method of using a sway bar assembly
is provided. The method can include the step of coupling an inner
sway bar with a first linking arm and a second linking arm. The
method can include the step of coupling a first outer sway bar with
the first linking arm. The method can include the step of coupling
a first coupling portion with the first outer sway bar. The method
can include the step of coupling a second outer sway bar with the
second linking arm. The method can include the step of coupling a
second coupling portion with the second outer sway bar. The method
can include the step of sliding the first coupling portion relative
to the first outer sway bar. The method can include the step of
disengaging the first coupling portion from the second coupling
portion.
[0023] The method can include the step of substantially preventing
rotation of the inner sway bar relative to the first linking arm
and the second linking arm. The method can include the step of
substantially preventing rotation of the first coupling portion
relative to the first outer sway bar. The method can include the
step of substantially preventing rotation of the second coupling
portion relative to the second outer sway bar. In some embodiments,
sliding the first coupling portion relative to the first outer sway
bar further comprises overcoming a biasing force. In some
embodiments, sliding the first coupling portion relative to the
first outer sway bar further comprises exerting a pressure on the
first coupling portion with a fluid. The method can include the
step of releasing the fluid. In some embodiments, disengaging the
first coupling portion with the second coupling portion further
comprises disengaging dogs of the first coupling portion with dogs
of the second coupling portion. The method can include the step of
disposing the inner sway bar within the first outer sway bar and
the second outer sway bar. In some embodiments, after disengaging
the first coupling portion with the second coupling portion, the
first outer sway bar and the second outer sway bar do not transmit
torque. The method can include the step of engaging the first
coupling portion with the second coupling portion such that the
first outer sway bar and the second outer sway bar transmit torque
as if the first outer sway bar and the second outer sway bar were
unitarily formed. In some embodiments, sliding the first coupling
portion relative to the first outer sway bar further comprises
sliding the first coupling portion away from the second coupling
portion. In some embodiments, sliding the first coupling portion
relative to the first outer sway bar further comprises sliding the
first coupling portion toward the second coupling portion.
[0024] In some embodiments, a method of using a sway bar assembly
is provided. The method can include the step of coupling an inner
sway bar with a first linking arm and a second linking arm. The
method can include the step of coupling a first outer sway bar
assembly with the first linking arm. The method can include the
step of coupling a second outer sway bar assembly with the second
linking arm. The method can include the step of engaging the first
outer sway bar assembly with the second outer sway bar assembly
such that the first outer sway bar assembly and the second outer
sway bar assembly transmit torque. The method can include the step
of disengaging the first outer sway bar assembly from the second
outer sway bar assembly such that the inner sway bar transmits
torque.
[0025] In some embodiments, engaging the first outer sway bar
assembly with the second outer sway bar assembly further comprises
biasing a portion of the first outer sway bar assembly toward the
second outer sway bar assembly. In some embodiments, engaging the
first outer sway bar assembly with the second outer sway bar
assembly further comprises releasing a fluid from a chamber. In
some embodiments, engaging the first outer sway bar assembly with
the second outer sway bar assembly further comprises engaging dogs
of the first outer sway bar assembly with dogs of the second outer
sway bar assembly. In some embodiments, engaging the first outer
sway bar assembly with the second outer sway bar assembly further
comprises transmit torque as if the first outer sway bar assembly
and the second outer sway bar assembly were unitarily formed. In
some embodiments, disengaging the first outer sway bar assembly
with the second outer sway bar assembly further comprises exerting
a pressure on a portion of the first outer sway bar assembly to
overcome a biasing force. In some embodiments, disengaging the
first outer sway bar assembly with the second outer sway bar
assembly further comprises filling a chamber with fluid to move a
portion of the first outer sway bar assembly relative to the second
outer sway bar assembly. In some embodiments, disengaging the first
outer sway bar assembly with the second outer sway bar assembly
further comprises disengaging dogs of the first outer sway bar
assembly with dogs of the second outer sway bar assembly. The
method can include the step of disposing the inner sway bar within
the first outer sway bar assembly and the second outer sway bar
assembly. In some embodiments, disengaging the first outer sway bar
assembly from the second outer sway bar assembly is performed
remotely from within the cab of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] These and other features, aspects and advantages of the
present sway bar assemblies are described herein with reference to
drawings of certain preferred embodiments, which are provided for
the purpose of illustration and not limitation. The drawings
contain twenty-one (21) figures.
[0027] FIG. 1 is a perspective view of a sway bar assembly.
[0028] FIG. 2 is an exploded view of the sway bar assembly of FIG.
1.
[0029] FIG. 3 is a perspective view of a first outer sway bar
including a first coupling of the sway bar of FIG. 1.
[0030] FIG. 4 is an exploded view of the first outer sway bar and
the first coupling of FIG. 1.
[0031] FIG. 5 is an exploded view of the first coupling of FIG.
1.
[0032] FIG. 6 is a perspective view of the movable component of
FIG. 1.
[0033] FIG. 7 is a perspective view of the hub of FIG. 1.
[0034] FIG. 8 is a perspective view of a second outer sway bar
including a second coupling of the sway bar of FIG. 1.
[0035] FIG. 9 is an exploded view of the second outer sway bar and
the second coupling of FIG. 1.
[0036] FIG. 10 is a perspective view of the second coupling of FIG.
1.
[0037] FIG. 11 is a perspective view of the housing of FIG. 1.
[0038] FIG. 12 is a perspective view of the first segment of the
housing of FIG. 1.
[0039] FIG. 13 is a longitudinal cross-sectional view of the
central segment of the housing taken along the line 11-11 of FIG.
11.
[0040] FIG. 14 is a perspective view of the second segment of the
housing of FIG. 1.
[0041] FIG. 15 is a perspective view of the first coupling and the
second coupling of FIG. 1 engaged with each other.
[0042] FIG. 16 is a side view of the first coupling and the second
coupling of FIG. 1 engaged.
[0043] FIG. 17 is a perspective view of the first coupling and the
second coupling of FIG. 1 disengaged.
[0044] FIG. 18 is a side view of the first coupling and the second
coupling of FIG. 1 disengaged.
[0045] FIG. 19 is a perspective view of a first hubcap and first
linking arm of the sway bar of FIG. 1.
[0046] FIG. 20 is a perspective view of a mounting plate and a
mounting bracket coupled to the housing of the sway bar of FIG.
1.
[0047] FIG. 21 is a perspective view of the mounting bracket and
mounting plate of FIG. 20.
DETAILED DESCRIPTION
[0048] Preferred embodiments of the sway bar assembly include two
(or possibly more) sway bars used to alter stiffness and anti-roll
characteristics of a vehicle. One or more of the two or more sway
bars may include portions that also be referred to as bars,
segments or portions herein. However, the use of the term "bar"
does not imply any particular cross-sectional shape or
configuration. The bar may be any suitable shape that permits the
engaging and disengaging of a larger diameter sway bar which
surrounds a smaller diameter sway bar. Certain embodiments are
illustrated and/or described herein.
[0049] Typically, the sway bar assembly controls movement of one
wheel relative to another wheel to stabilize the vehicle. The
characteristics of the sway bar, including the diameter of the sway
bar, will impact the anti-roll characteristics of the vehicle.
Often a sway bar is provided that spans between two linking arms,
which are mounted relative to the wheels or suspension components
of the vehicle. For convenience, the sway bar assembly is referred
to as having a driver side and a passenger side. The sway bar
assembly has a longitudinal axis which extends from the driver side
to the passenger side. These, and other relative terms (top,
bottom, above, below, etc.) are used for convenience and with
respect to the particular orientation shown in the referenced
figures and are not intended to be limiting, unless otherwise
indicated or made clear from the particular context. Thus, the sway
bar assembly can also be used in other orientations, or adapted for
use in orientations other than those illustrated.
[0050] The embodiments disclosed herein are well-suited for use in
off-road environments. In off-road environments, it is usually
preferable to minimize or eliminate the stiffness of the sway bar
in order to better traverse the terrain. In contrast, in other
conditions, it is usually preferable to minimize vehicle roll by
using a sufficiently stiff sway bar. For example, a stiffer sway
bar is well-suited for negotiating tighter turns. However, the
disclosed embodiments can also be used in, or adapted for use in,
other applications as well.
[0051] With reference to FIGS. 1 and 2, a sway bar assembly 20 can
include an outer sway bar 21 and an inner sway bar 23. The outer
sway bar 21 comprises a first outer sway bar 22 and a second outer
sway bar 24 that can be engaged or disengaged to form a rigid body.
The outer sway bar further includes a first coupling portion 26 and
a second coupling portion 28. One of the couplings 26, 28, or a
portion of one of the couplings 26, 28, is movable relative to the
other of the couplings 26, 28. In the illustrated arrangement, a
portion of the first coupling portion 26 is movable to engage or
disengage the second coupling portion 28. However, in other
embodiments, this arrangement could be reversed such that the
second coupling portion 28, or a portion of the second coupling
portion 28 could be movable.
[0052] The illustrated sway bar assembly 20 permits adjustment of
the stiffness of the sway bar assembly 20 by engaging or
disengaging a larger diameter sway bar. The adjustment can be
initiated (and/or caused) from within the vehicle compartment. For
example, the adjustment can be initiated through a switch or other
mechanism accessible to the driver (e.g., within the cab of the
vehicle). The adjustment can disengage the larger diameter sway
bar. When the larger diameter sway bar is disengaged, a smaller
diameter sway bar continues to stabilize the vehicle. When the
larger diameter sway bar is engaged, both the larger diameter sway
bar and the smaller diameter sway bar stabilize the vehicle.
[0053] The illustrated sway bar assembly 20 provides a default
position that engages the larger diameter sway bar. The default
position is that a first coupling portion 26 and a second coupling
portion 28 are engaged or locked together. The default position
provides anti-roll characteristics and a stiff sports-car feel for
maneuvering on streets and the like. Because the default position
engages the larger diameter sway bar, if a chamber that pressurizes
to disengage the larger diameter sway bar leaks fluid or otherwise
loses pressure, then the sway bar returns to the default (i.e.,
engaged) position. If the inlet or other features of the fluid
exchange fail, then the sway bar remains or returns to the default
(i.e., engaged) position.
[0054] In the illustrated configuration, the sway bar assembly 20
can be considered to feature a multi-stage sway bar. In some
configurations, the sway bar assembly 20 can include a two stage
sway bar. The first stage relies on both the inner, smaller
diameter sway bar and the outer, larger diameter sway bar to
provide stabilization. The second stage relies on only the inner,
smaller diameter sway bar to provide stabilization and the outer,
larger diameter sway bar is disengaged. The inner sway bar is more
compliant, which does not impede articulation of the vehicle to the
extent of the larger diameter sway bar. The sway bar assembly 20
can be adjusted from the first stage to the second stage and vice
versa from inside the cab of the vehicle. In some embodiments, an
activation mechanism can supply fluid to the sway bar assembly 20
to disengage the outer, larger diameter sway bar. The fluid can be
discharged such that the sway bar assembly 20 returns to the
default position (i.e., the outer, larger diameter sway bar
engaged).
[0055] In the illustrated arrangement, the first outer sway bar 22
has a length that is substantially equal to a length of the second
outer sway bar 24. In some configurations, the first outer sway bar
22 and the second outer sway bar 24 have different lengths with one
being shorter than the other. The first outer sway bar 22 and the
second outer sway bar 24, when combined, may equal a length of the
inner sway bar 23 or may approximately equal the length of the
inner sway bar 23, keeping in mind a desire to provide two coaxial
sway bars yet allow one of the sway bars to separate along its
length. The first outer sway bar 22 and the second outer sway bar
24 may define a hollow circular cross section. The inner sway bar
23 may define a circular or hollow circular cross-section. Other
configurations are possible.
[0056] In some configurations, one, or both, of the first outer
sway bar 22 and the second outer sway bar 24 defines a diameter
D.sub.O that is greater than a diameter D.sub.I of the inner sway
bar 23. For example, the diameter D.sub.O can be 2 times greater
than the diameter D.sub.I. For example, in some embodiments, the
cross-sectional diameter of the inner sway bar (not including the
hubcaps) is less than 3/4 inch, less than 5/8 inches, less than 1/2
inch and, preferably, is 5/8 inches (or any value within the
aforementioned range). The inner sway bar 23 can be solid. In some
embodiments, the inner sway bar 23 provides a desired low level of
vehicle stabilization.
[0057] The first outer sway bar 22 and the second outer sway bar 24
can be hollow to accept the inner sway bar 23 therein. The
cross-sectional diameter of the outer sway bar (not including the
couplings) is less than 1.50 inches, less than 1.25 inch, less than
1 inch and, preferably, is 1.25 inches (or any value within the
aforementioned range). The wall thickness of the outer sway bar is
less than 5/16 inches, less than 1/4 inches, less than 3/16 inches,
preferably, is 1/4 inches (or any value within the aforementioned
range). The inner diameter of the outer sway bar is less than 3/4
inch, less than 11/16 inches, less than 5/8 inches, preferably, is
0.7 inches (or any value within the aforementioned range).
[0058] The sway bar assembly 20 illustrated in FIGS. 1 and 2 is
arranged and configured in accordance with certain features,
aspects and advantages of the present invention. In the illustrated
arrangement, the sway bar assembly 20 includes three sway bar
segments: the first outer sway bar 22, the second outer sway bar
24, and the inner sway bar 23. The inner sway bar 23 is retained
within the first outer sway bar 22 and the second outer sway bar
24. In some embodiments, the inner sway bar 23 is coaxial within
the first outer sway bar 22 and the second outer sway bar 24.
[0059] The sway bar assembly 20 includes the first coupling portion
26 and the second coupling portion 28. One or both of the first
coupling portion 26 and the second coupling portion 28 are movable
between an engaged position and a disengaged position. In some
configurations, as discussed below, the sway bar assembly 20 can
include one or more dogs that permit the sway bar assembly 20 to be
selectively locked in the engaged position and the disengaged
position. In addition, the sway bar assembly 20 may include
engagement features (e.g., splines, flutes, gears, etc.) interposed
between some or all of the first outer sway bar 22, the second
outer sway bar 24, the inner sway bar 23, the first coupling
portion 26, the second coupling portion 28, and various other
components to couple the components in specified manners.
Alternatively, some or all of the segments of the sway bar assembly
20 may include bearing surfaces that permit components to
longitudinally slide relative to one another.
[0060] The sway bar assembly 20 is configured to be secured to a
vehicle, for example in the region of the front wheels of the
vehicle. For example, the sway bar assembly 20 includes a first
linking arm 100 and a second linking arm 102 that permits the sway
bar assembly 20 to be secured to the vehicle. The first linking arm
100 can be joined to a first end of the inner sway bar 23 and/or
the first outer sway bar 22 and the second linking arm 102 can be
joined to a second end of the inner sway bar 23 and/or the second
outer sway bar 24. A first hubcap 104 and a second hubcap 106 can
join the first linking arm 100 and the second linking arm 102 with
the ends of the inner sway bar 23, for example but without
limitation. The first hubcap 104 can be coupled to the first
linking arm 100 and the second hubcap 106 can be coupled to the
second linking arm 102. Preferably, the first hubcap 104 and the
first linking arm 100 can be coupled to the first outer sway bar 22
and the inner sway bar 23 while the second hubcap 106 and the
second linking arm 102 can be coupled to the second outer sway bar
24 and the inner sway bar 23. Moreover, the sway bar assembly 20
may be connected to the vehicle in any suitable manner, such as by
mounting plates and brackets described herein. In the arrangement
illustrated in FIG. 1, the sway bar assembly 20 spans between the
driver and passenger sides of the vehicle.
[0061] With reference now to FIGS. 3 and 4, the first outer sway
bar 22 can include a central lumen 30. The lumen 30 can accommodate
the inner sway bar 23. The first outer sway bar 22 includes a first
end 32 and a second end 34. The first end 32 can include an
engagement feature 36. In the illustrated embodiment, the
engagement feature 36 of the first end 32 is a plurality of teeth.
The plurality of teeth can be disposed along an outer surface of
the first end 32. The first end 32 engages the first linking arm
100. The first linking arm 100 can include an engagement feature
108 (see FIG. 19) to complement the engagement feature 36 of the
first end 32 of the first outer sway bar 22. In the illustrated
embodiment, the engagement feature 108 of the first linking arm 100
is a plurality of teeth. The plurality of teeth can be disposed
along an inner lumen of the first linking arm 100. The coupling
between the first outer sway bar 22 and the first linking arm 100,
therefore, can be via a splined connection. Such a configuration is
desirable given the forces being transferred through the
connection.
[0062] The second end 34 of the first outer sway bar 22 can include
an engagement feature 38. In the illustrated embodiment, the
engagement feature 38 of the second end 34 is a plurality of teeth.
The engagement feature 38 of the second end 34 can be different or
the same as the engagement feature 36 of the first end 32 of the
first outer sway bar 22. The second end 34 of the first outer sway
bar 22 engages the first coupling portion 26. The first coupling
portion 26 can include an engagement feature 40 to complement the
engagement feature 38 of the second end 34. In the illustrated
embodiment, the engagement feature 40 of the first coupling portion
26 is a plurality of teeth. In some embodiments, the second end 34
can include one or more retaining members (e.g., O-rings) that
facilitate the retention of second end 34 of the first outer sway
bar 22 within the first coupling portion 26.
[0063] The engagement features facilitate the coupling of
components. In some embodiments, the engagement features described
herein can include gears, teeth, flutes, splines, grooves,
channels, keys or any other feature known in the art to couple
components. In some embodiments, the engagement features prevent
rotation of one component relative to another component. In some
embodiments, the engagement features support movement of the
components while maintaining the engagement of components. For
example, the engagement features extend longitudinally, permitting
longitudinally sliding of the components relative to each other. In
some embodiments, the engagement features are constructed of a
material for low sliding resistance and durability.
Moveable Sleeve
[0064] FIGS. 5-8 are perspective and exploded views of the first
coupling portion 26. The first coupling portion 26 can be
configured for selective decoupling with the second coupling
portion 28. In other words, the first coupling portion 26 can
include at least one component that is configured to selectively
couple with the second coupling portion 28.
[0065] As shown in FIG. 5, the illustrated first coupling portion
26 comprises a hub 42 and a movable sleeve 44. The hub 42 can
include the engagement feature 40 that complements the second end
34 of the first outer sway bar 22. In the illustrated embodiment,
the engagement feature 40 of the hub 42 can include a plurality of
teeth that are arranged and configured to engage the teeth of the
second end 34 of the first outer sway bar 22. The plurality of
teeth can be disposed along an inner lumen 45 of the hub 42. Thus,
a splined coupling can be defined between the hub 42 and the first
outer sway bar 22.
[0066] The hub 42 can include a second engagement feature 46 to
engage a portion of the movable sleeve 44. In the illustrated
embodiment, the hub 42 can include a plurality of radially
outwardly projecting ridges. The plurality of ridges can be
disposed along an outer surface of the hub 42. In some
configurations, the ridges slope gently between peaks and valleys.
The plurality of ridges can form a flower-petal shape, as
shown.
[0067] The movable sleeve 44 can include a second engagement
feature 48 to complement the second engagement feature 46 (i.e.,
the ridges) of the hub 42. In the illustrated embodiment, the
movable sleeve 44 can include a plurality of recesses to engage the
ridges of the hub 42. The plurality of recesses can be disposed
along an inner lumen 49 of the movable sleeve 44. In the
illustrated configuration, the recesses receive only a portion of
the full height of the ridges. While the illustrated configuration
is generally symmetrical, it is possible to have asymmetric or a
patterned configuration as well in which the height or radial width
of the each of the ridges are not consistent one to the next. In
the illustrated configuration, the interfacing portions of the
second engagement features 46, 48 are generally smooth without
sharp points. Other configurations are possible.
[0068] The hub 42 is configured to be received within the movable
sleeve 44 with the second engagement features 46, 48 engaged with
each other. The first coupling portion 26 can be considered a
shuttle mechanism with the movable sleeve 44 shuttling on the hub
42 while the second engagement features 46, 48 of the first
coupling portion 26 maintain a desired axial orientation of the
movable sleeve 44 relative to the hub 42. The movable sleeve 44 can
shift axially between a first position and a second position. In
some embodiments, the movable sleeve 44 is the only axially
shiftable component 44 of the sway bar assembly 20. The second
engagement features 46, 48 reduce or eliminate the likelihood of
rotation of the movable sleeve 44 with respect to the hub 42 and,
therefore, the first outer sway bar 22. Reducing or eliminating the
likelihood of rotation of the movable sleeve 44 enables the first
coupling portion 26 to properly engage with the second coupling
portion 28, as described below.
[0069] Referring back to FIG. 2, the movable sleeve 44 and the
second coupling portion 28 can define a clutch. In some
configurations, the movable sleeve 44 and the second coupling
portion 28 can define a dog clutch. Referring to FIG. 6, the
movable sleeve 44 includes a plurality of teeth 50 and engagement
surfaces (i.e., the recesses) disposed between the plurality of
teeth 50. The teeth 50 are shaped to interlock with the teeth 72 of
the second coupling portion 28 and abut the engagement surfaces
(i.e., the recesses) of the second coupling portion 28, as shown in
FIGS. 15 and 16. As shown in FIG. 6, the teeth 50 are located on a
forward face of the movable sleeve 44. The teeth 50 extend
longitudinally (i.e., axially) along the axis of the sway bar
assembly 20. The illustrated embodiment shows four teeth 50 on the
movable sleeve 44, but fewer or greater numbers of teeth are
contemplated (e.g., three, four, five, six, seven, eight, nine,
ten). The illustrated embodiment shows equally spaced teeth 50 on
the movable sleeve 44, but different configurations are
contemplated. Preferably, the teeth 50, 72 are offset from one
another (e.g., rotated clockwise with respect to each other) to
permit interlocking. If the teeth 50, 72 are slightly misaligned,
then the teeth 50, 72 will mash together until alignment is reached
due to the biasing force of a spring 56. In some embodiments, the
teeth 50, 72 will rarely interlock out of phase (e.g., rotated so
the teeth 50 are misaligned-indexed one slot from a desired
position) based on the inherent limits of vehicular roll and based
on the number of degrees of rotation between the second coupling
portion 28 and the first coupling portion 26 (i.e., movable sleeve
44).
[0070] Referring to FIGS. 2-5, the first outer sway bar 22 is held
in rotational position relative to the first linking arm 100 by the
engagement feature 36 of the first end 32 coupled with the
engagement feature 108 of the first linking arm 100. The hub 42 is
held in rotational position relative to the first outer sway bar 22
by the engagement feature 40 coupled with the engagement feature 38
of the second end 34 of the first outer sway bar 22. The movable
sleeve 44 is held in rotational position relative to the hub 42 by
the second engagement feature 48, which is rotationally coupled
with the second engagement feature 46 of the hub 42. Thus, the
movable sleeve 44 generally is fixed against rotation (as opposed
to rotation caused by torsion of the first outer sway bar 22)
relative to the first linking arm 100.
Fluid Chamber
[0071] As shown in FIGS. 6 and 13, the outer surface of the movable
sleeve 44 can include a plurality of circumferential grooves. In
some embodiments, the movable sleeve 44 can include a first groove
52 and a second groove 74. A first sealing member 114 (see FIG. 13)
is configured to be retained in the groove 52 and a second sealing
member 116 (see FIG. 13) is configured to be retained in the groove
74. The sealing members 114, 116 can be O-rings, for example but
without limitation.
[0072] In the illustrated configuration, the outer surface of the
movable sleeve 44 can have at least two diameters. The outer
surface of the movable sleeve 44 can have a larger diameter 43
toward the hubcap 104. The outer surface of the movable component
can have a smaller diameter toward the teeth 50. The first groove
52 can be located on the smaller diameter section of the movable
sleeve 44, closer to the teeth 50. The second groove 74 can be
located on the larger diameter section 43 of the movable sleeve 44,
closer to the hubcap 104. The sealing members 114, 116 create a
seal between the movable sleeve 44 and the housing, as describe
herein.
[0073] Referring to FIGS. 6 and 13, as described above, the inner
surface of the movable sleeve 44 can be defined by the lumen 45.
The illustrated lumen 45 can be stepped. In other words, the
illustrated lumen 45 can include a first portion that is smaller in
diameter and a second portion that is larger in diameter. The
smaller diameter portion can be positioned within the portion of
the moveable sleeve that includes the second engagement feature 48.
The larger diameter portion can be positioned within the portion of
the movable sleeve 44 that underlies the second groove 74.
[0074] The stepped lumen 45 provides space for a spring 56 to be
disposed within the movable sleeve 44. The lumen 45 in the
illustrated sleeve 44 includes a stepped surface 51 that extends in
a generally radial direction. The stepped surface 51 defines a
bearing surface for the spring 56. The spring 56 can abut the
stepped surface 51 in the lumen 45 to bias the movable sleeve 44
toward the second coupling portion 28.
[0075] The sway bar assembly 20 can include an additional spacer
47, shown in FIGS. 2 and 13. The spacer 47 can define an additional
surface against which the spring 56 can bear. Thus, the spring 56
can be compressed between the spacer 47 and the stepped surface 51
of the movable sleeve 44. In some configurations, the spacer 47 can
define a mechanical stop for the movable sleeve 44. Thus, in some
configurations, the spacer 47 can help limit the axial travel of
the sleeve 44 along the first outer sway bar 22 and, thereby, also
limit compression of the spring 56. In some configurations, the
spacer 47 can bear against a surface of the first outer sway bar
22.
[0076] FIGS. 8-10 are perspective and exploded views of the second
outer sway bar 24 and the second coupling portion 28. The second
outer sway bar 24 can include a central lumen 58 through which the
inner sway bar 23 can extend. Like the first outer sway bar 22, the
inner sway bar 23 can extend fully through the second outer sway
bar 24 as well.
[0077] The second outer sway bar 24 includes a first end 60 and a
second end 62. The first end 60 can include an engagement feature
64. In the illustrated embodiment, the engagement feature 64 of the
first end 60 is a plurality of teeth. The plurality of teeth can be
disposed along an outer surface of the first end 60. The first end
60 engages the second linking arm 102 (see FIG. 2). The second
linking arm 102 can include an engagement feature (not shown) to
complement the engagement feature 64 of the first end 60. In the
illustrated embodiment, the engagement feature of the second
linking arm 102 can be a plurality of teeth. The plurality of teeth
can be disposed along an inner lumen of the second linking arm 102,
similar to the first linking arm 100 shown in FIG. 19.
[0078] The second end 62 also can include an engagement feature 66.
The engagement feature 66 of the second end 62 can be different or
the same as the engagement feature 64 of the first end 60. In the
illustrated embodiment, the engagement feature 66 of the second end
62 is a plurality of teeth. The plurality of teeth can be disposed
along an outer surface of the second end 62.
[0079] With reference to FIG. 9, the second end 62 engages the
second coupling portion 28. The second coupling portion 28 can
include an engagement feature 68 to complement the engagement
feature 66 of the second end 62 of the second outer sway bar 24. In
the illustrated embodiment, the engagement feature 68 of the second
coupling portion 28 is a plurality of teeth. The plurality of teeth
can be disposed along an inner lumen of the second coupling portion
28. In some embodiments, the second end 62 can include a retaining
member (e.g., O-rings).
[0080] As mentioned above, the movable sleeve 44 and the second
coupling portion 28 can define a clutch. Referring to FIG. 10, the
second coupling portion 28 includes a plurality of teeth 72 and an
engagement surface between the teeth 72. The teeth 72 are shaped to
interlock with the teeth 50 of the movable sleeve 44 and abut the
engagement surface of the movable sleeve 44. As shown in FIG. 10,
the teeth 72 are located on a forward face of the second coupling
portion 28. The teeth 72 extend longitudinally along the axis of
the sway bar assembly 20. The illustrated embodiment shows four
teeth 72 on the second coupling portion 28, but fewer or greater
dogs are contemplated (e.g., three, four, five, six, seven, eight,
nine, ten). The illustrated embodiment shows equally spaced teeth
72 on the second coupling, but different configurations are
contemplated as discussed above. Preferably, the teeth 50, 72 are
offset from one another (e.g., rotated clockwise with respect to
each other) to permit interlocking.
[0081] Referring to FIGS. 2 and 8, the second outer sway bar 24 is
held in rotational position relative to the second linking arm 102
by the engagement feature 64 of the first end 60 coupled with the
engagement feature of the second linking arm 102. The second
coupling portion 28 is held in rotational position relative to the
second outer sway bar 24 by the engagement feature 68 coupled with
the engagement feature 66 on the second end 62 of the second outer
sway bar 24. Accordingly, second coupling portion 28 generally is
fixed against rotation (as opposed to rotation caused by torsion of
the first outer sway bar 22) relative to the second linking arm
102.
[0082] FIGS. 11-14 are perspective and cross-sectional views of the
housing. The illustrated housing includes three segments: a first
segment 76, a central segment 78, and a second segment 80. The
first segment 76, the central segment 78, and the second segment 80
include a central lumen there through. The first segment 76
includes a lumen 82 configured to receive the first outer sway bar
22 and the inner sway bar 23. In some embodiments, the first
segment 76 includes a recess to abut the spacer 47. The central
segment 78 includes a lumen 84 configured to accept the first
coupling portion 26, the second coupling portion 28, the first
outer sway bar 22, the second outer sway bar 24, and the inner sway
bar 23. The second segment 80 includes a lumen 86 configured to
accept the second outer sway bar 24 and the inner sway bar 23. In
some embodiments, the second segment 80 includes a recess to abut
the second coupling portion 28. The housing can include an inlet
112 or port configured to accept a fluid. In some embodiments, the
inlet 112 is located on the second segment 80.
[0083] The first segment 76, the central segment 78, and the second
segment 80 can be coupled in any suitable manner. In the
illustrated arrangement, the first segment 76, the central segment
78, and the second segment 80 are separate components coupled
together by one or more suitable fasteners, such as rivets or
screw, for example. The first segment 76 and the second segment 80
include an elongated body portion that is coupled to the wall of
the central segment 78. Preferably, the elongated body portion of
the first segment 76, the central segment 78, and the elongated
body portion of the second segment 80 have the same diameter. That
is, in some arrangements, the elongated body portion of the first
segment 76, the central segment 78, and the elongated body portion
of the second segment 80 is of substantially the same height. Such
an arrangement increases the overall strength and rigidity of the
housing. In some embodiments, the central segment 78 is unitary
with, or formed from the material of, the first segment 76 and/or
the second segment 80. Each of the first segment 76 and the second
segment 80 can define a ramped surface. The ramped surface is
angled to reduce the overall size and shape of the housing. Other
shapes and configurations for the housing are contemplated.
[0084] The first segment 76 includes a groove 88. The first outer
sway bar 22 includes a groove 90, see FIG. 4. A retaining member
92, for example an O-ring, is retained within the grooves 88, 90.
The second segment 80 includes a groove 94. The second outer sway
bar 24 includes a groove 96, see FIG. 8. A retaining member 98, for
example an O-ring, is retained within the grooves 94, 96. The
retaining members 92, 98 permit flexibility of the first outer sway
bar 22 with respect to the second outer sway bar 24. The retaining
members 92, 98 can be wiper seals to reduce the likelihood of
particles entering the housing. The housing protects the first
coupling portion 26 and the second coupling portion 28 from foreign
particles, reducing the likelihood of excess wear on the first
coupling portion 26 and the second coupling portion 28. The housing
does not necessarily rigidly couple the first outer sway bar 22 and
the second outer sway bar 24. Rather, the housing is maintained at
a set distance from the first outer sway bar 22 and the second
outer sway bar 24 by the flexible retaining members 92, 98.
[0085] FIG. 13 is a longitudinal cross-sectional view of the
central segment 78 taken along the line 11-11 of FIG. 11 with the
movable sleeve 44, the hub 42, and the spacer 47 disposed within.
The central segment 78 includes the lumen 84. The lumen 84 includes
a smaller diameter portion 83 and a larger diameter portion 85. As
mentioned herein, the movable sleeve 44 can include the first
groove 52 and the second groove 74. The first sealing member 114
can be retained in the groove 52 and the second sealing member 116
can be retained in the groove 74. The first sealing member 114 can
abut the smaller diameter portion 83 of the central segment 78. The
second sealing member 116 can abut the larger diameter portion 85
of the central segment 78. The sealing members 114, 116 can slide
relative to the lumen 84. The sealing members 114, 116 can create a
fluid seal between the movable sleeve 44 and the central segment
78.
[0086] In some embodiments, a variable volume chamber 79 is created
between the movable sleeve 44 and the central segment 78. The
chamber 79 can accept a fluid. The fluid can be liquid or gas. As
the chamber 79 is filled with fluid, the fluid exerts pressure on
the movable sleeve 44. For example, in the illustrated
configuration, a surface defined by the step between the smaller
diameter portion and the larger diameter portion of the sleeve 44
can receive the force of the fluid in the chamber 79, which causes
movement of the movable sleeve 44.
[0087] The movable sleeve 44 moves to enlarge the chamber 79 by
traveling axially along the first outer sway bar 22 toward the
spacer 47. The movable sleeve 44 slides longitudinally within the
central segment 78 in response to a fluid entering the chamber 79.
FIG. 13 shows the movable component abutting the spacer 47,
preventing further longitudinal movement. The movable sleeve 44
slides along the hub 42. The movable sleeve 44 is resists rotation
with respect to the hub 42 due the engagement features 46, 48. The
movable sleeve 44 compresses the spring 56 as it moves in response
to a fluid entering the chamber 79. The force exerted by the fluid
overcomes the biasing force of the spring 56, as described
herein.
[0088] FIGS. 15 and 16 are perspective and side views of the first
coupling portion 26 and the second coupling portion 28 engaged.
When the two portions 26, 28 are engaged, the plurality of teeth 50
of the movable sleeve 44 of the first coupling portion 26 engage
the plurality of teeth 72 of the second coupling portion 28. In
some embodiments, a face of the first coupling portion 26 abuts the
plurality of teeth 72 on the second coupling portion 28 and/or a
face of the second coupling portion 28 abuts the plurality of teeth
50 on the movable sleeve 44. The movable sleeve 44 is biased toward
the second coupling portion 28 by the spring 56. The movable sleeve
44 slides along the hub 42 due to the force of the spring 56 until
the teeth 50, 72 interlock. The movable component is biased in the
direction of the arrow shown in FIG. 15.
[0089] In the engaged configuration, the first outer sway bar 22 is
engaged with the second outer sway bar 24. The first outer sway bar
22 (not shown) is coupled to the hub 42 of the first coupling
portion 26. The hub 42 is coupled to the movable sleeve 44 via the
second engagement features 46, 48. The spring 56 can be disposed
within the movable sleeve 44 and biases the movable sleeve 44
toward the second coupling portion 28. The movable sleeve 44 slides
longitudinally along the second engagement features 46 under the
influence of the spring 56, toward the second coupling portion 28.
The plurality of teeth 50 of the movable sleeve 44 engage with the
plurality of teeth 72 on the second coupling portion 28. The second
coupling portion 28 is coupled to the second sway bar 24 (not
shown).
[0090] Referring again to FIG. 15, in the engaged configuration,
the first coupling portion 26 and the second coupling portion 28
engage to form a rigid body. The first outer sway bar 22, the
second outer sway bar 24, the first coupling portion 26, and the
second coupling portion 28 form a rigid body. The rigid body acts
as a unitary bar to stabilize the vehicle. The rigid body is
capable of transmitting torque as if the outer sway bar were
unitarily formed. The first outer sway bar 22 and the second outer
sway bar 24 have a larger diameter than the inner sway bar 23. Due
to the design including the diameter of the first outer sway bar 22
and the second outer sway bar 24, the vehicle has different
characteristics related to roll and handling when the first
coupling portion 26 is engaged with the second coupling portion 28.
In some embodiments, the default position is the engaged
configuration wherein the first coupling portion 26 and the second
coupling portion 28 engage.
[0091] FIGS. 17 and 18 are perspective and side views of the first
coupling portion 26 and the second coupling portion 28 disengaged.
As mentioned herein, the chamber 79 can be created between the
movable sleeve 44 and the central segment 78. As the chamber 79 is
filled with fluid, the movable sleeve 44 will slide along the hub
42. The movable sleeve 44 moves longitudinally away from the second
coupling portion 28.
[0092] In the disengaged configuration, the first outer sway bar 22
is disengaged from the second outer sway bar 24. As mentioned
herein, the first outer sway bar 22 is coupled to the hub 42 of the
first coupling portion 26. The hub 42 is coupled to the movable
sleeve 44 via the second engagement features 46, 48. To achieve the
disengaged configuration, the spring 56 is compressed by the fluid,
moving the movable sleeve 44 away from the second coupling portion
28. The movable sleeve 44 slides longitudinally along the second
engagement features 46 away from the second coupling portion 28.
The plurality of teeth 50 of the movable sleeve 44 disengage with
the plurality of teeth 72 on the second coupling portion 28. The
second coupling portion 28 is coupled to the second outer sway bar
24.
[0093] In the disengaged configuration, the first coupling portion
26 and the second coupling portion 28 are not engaged and do not
form a rigid body. The first outer sway bar 22 is uncoupled from
the second outer sway bar 24. In the disengaged configuration, the
inner sway bar 23 extends between the passenger side and the driver
side, from the first hubcap 104 to the second hubcap 106. The inner
sway bar 23 controls roll of the body of the vehicle. The inner
sway bar 23 has a smaller diameter than the first outer sway bar 22
and the second outer sway bar 24. Due to the design of the inner
sway bar 23, including the diameter of the inner sway bar 23, the
vehicle has different characteristics related to roll and handling.
The inner sway bar 23 is more compliant, leading to a less stiff
feel for the driver.
[0094] The fluid will maintain the disengaged configuration until
the pressure is released from the chamber 79. When the pressure is
released from the chamber 79 between movable sleeve 44 and the
central segment 78 of the housing, the spring 56 biases the movable
sleeve 44 toward the second coupling portion 28. The sway bar
assembly 20 returns to the default position, which is the engaged
configuration in the illustrated embodiment. If the chamber 79
leaks fluid, then the sway bar assembly 20 also returns to the
default position. If the inlet 112 or other features of the fluid
exchange fail, then the sway bar assembly 20 remains in, or returns
to, the default position.
[0095] FIG. 19 is a perspective view of the first hubcap 104 and
the first linking arm 100 of the sway bar assembly 20. As mentioned
herein, the first end 32 of the first outer sway bar 22 can include
an engagement feature 36. The first linking arm 100 can include an
engagement feature 108 to complement the engagement feature 36 of
the first end 32. In some embodiments, the first end 32 can include
retaining member (e.g., O-rings) that facilitate the retention of
the first outer sway bar 22 within the first linking arm 100. In
some embodiments, the first linking arm 100 can include a clamp 118
near the engagement feature 108. The clamp 118 can be compressed to
engage the engagement features 36, 108. The clamp 118 can
facilitate the assembly of the sway bar assembly 20. The linking
arm 102 (not shown) can include engagement features 110 (not shown)
and similar features to the linking arm 100 as shown in FIG. 19. In
some embodiments, the first end 60 of the second outer sway bar 24
can include retaining member (e.g., O-rings) that facilitate the
retention of the second outer sway bar 24 within the second linking
arm 102.
[0096] The first hubcap 104 can be rigidly coupled to the first
linking arm 100. The first hubcap 104 can include seat 120. The
seat 120 can engage the first end 122 of the inner sway bar 23. The
first end 122 of the inner sway bar 23 can have non-uniform shape.
The non-uniform shape can reduce or eliminate the likelihood of
rotation of the inner sway bar 23 with respect to the first hubcap
104. The second end (not shown) of the inner sway bar 23 and the
second hubcap 106 can have similar features, as shown in FIG. 19.
The illustrated first hubcap 104 includes fasteners, such as
screws. The illustrated fasteners are generally cylindrical in
shape. However, other suitable shapes may also be used. In some
embodiments, the fasteners may compress the clamp 118 of the first
linking arm 100. Although four fasteners are shown, other numbers
of fasteners are also possible. The fasteners are configured to
engage mounting holes in the first hubcap 104 and mounting holes in
the first linking arm 100.
[0097] The components of the sway bar assembly 20 may be
constructed of any suitable material and by any suitable
manufacturing process. However, in some embodiments, the components
of the sway bar assembly 20 are constructed from suitable metal
materials (e.g., steel materials). The components can be shaped by
any suitable process, including bending or roll forming techniques,
for example but without limitation.
[0098] FIGS. 20 and 21 are perspective views of a mounting bracket
126 and a mounting plate 128. The mounting bracket 126 can be
coupled to the housing 76, 78, 80. In the illustrated embodiment,
the mounting bracket 126 is coupled to the first segment 76 and the
second segment 80. The mounting bracket 126 can include holes to
accept the fasteners that couple the first segment 76 and the
second segment 80 to the central segment 78. The mounting bracket
126 can span the central segment 78, and in some embodiments, is
about the same length as the central segment 78.
[0099] The mounting plate 128 can be coupled to the mounting
bracket 126. In some embodiments, the mounting plate 128 can be
configured to replace or can be a stock mounting plate 128 that can
be coupled to a stock sway bar. In other embodiments, the mounting
plate 128 is specially designed to support the sway bar assembly
20. The mounting plate 128 can couple to the underside of the
vehicle. The mounting plate 128 can be designed based on the make
and the model of the vehicle. The mounting plate 128 can be
designed to align with the original mount points of the vehicle.
The mounting plate 128 and other components of the sway bar
assembly 20 can be connected to the vehicle by using suitable
fasteners. The mounting bracket 126 and the mounting plate 128 can
reduce or eliminate the likelihood of the first outer sway bar 22
and the second outer sway bar 24 rotating significantly when the
first outer sway bar 22 and the second outer sway bar 24 are
disengaged.
[0100] In operation, the sway bar assembly 20 is coupled to the
vehicle with the mounting plate 128 and the mounting bracket 126.
Once mounted, the linking arms 100, 102 can be connected to the
vehicle. The linking arms 100, 102 can be moved relative to one
another (if necessary) along the first outer sway bar 22 and the
second outer sway bar 24 when being coupled together. A fluid
source can be connected to the fluid inlet 112. The fluid source
can be a source of compressed air or a pump or the like. The fluid
source can be actuated in any suitable manner to disengage the
first coupling portion 26 from the second coupling portion 28. In
some configurations, the fluid source can be controlled remotely
relative to the rest of the sway bar assembly 20, such as from
within the cab of the vehicle. In some configurations, a switch,
pushbutton or the like can be mounted within the cab of the
vehicle. Operation of the switch, pushbutton or the like can cause
pressurization of the chamber within the housing of the sway bar
assembly 20.
[0101] Although this invention has been disclosed in the context of
certain preferred embodiments and examples, it will be understood
by those skilled in the art that the present invention extends
beyond the specifically disclosed embodiments to other alternative
embodiments and/or uses of the invention and obvious modifications
and equivalents thereof. In particular, while the present sway bars
have been described in the context of particularly preferred
embodiments, the skilled artisan will appreciate, in view of the
present disclosure, that certain advantages, features and aspects
of the assemblies may be realized in a variety of other
applications, many of which have been noted above. Additionally, it
is contemplated that various aspects and features of the invention
described can be practiced separately, combined together, or
substituted for one another, and that a variety of combination and
sub combinations of the features and aspects can be made and still
fall within the scope of the invention. Thus, it is intended that
the scope of the present invention herein disclosed should not be
limited by the particular disclosed embodiments described above,
but should be determined only by a fair reading of the claims.
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